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    '65 heater box rebuild

    My heater box was in bad shape; the clue was the 'cardboard' defroster plenum decomposing, so I decided to pull the whole works and see what I could do. I found out the previous owner had been in there before me- I'm guessing he replaced the heater core, as it was like new, but jeez, what a hack job he did!

    The end of the fiberglass box was missing a big chunk, and the fresh air bellows that connects to the cowl intake was made out of a piece of thin plastic that was formed into a circle & screwed to both the box & the cowl.

    So I ordered a new plastic plenum, a box seal kit, new defroster tubes, a new 2-speed motor and a new bellows, along with a small fiberglass repair kit. I used the plastic sheet from the homemade bellows to build a form for the end of the box, riveted in place, and laid up the 'glass to create a new end for the missing chunk.
    Good as new! Here's some before, during & after photos:
    Attached Images Attached Images
    1965 Ranchero Deluxe
    factory 289 4 speed car

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